Hardtop structure for boats and method for making same

ABSTRACT

A multi-component hardtop is adapted for mounting above an operator station of a boat or the like. The hardtop includes a tubular frame which is provided with a self-trimming edge adapted to mount a sheet-like panel in a substantially flush orientation relative to an upper or lower edge of the frame.

PRIORITY

This application is a continuation-in-part of U.S. patent application Ser. No. 11/019,704, filed Dec. 22, 2004, which claims priority to U.S. Provisional Patent Application Ser. No. 60/532,794 filed Dec. 23, 2003, the disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention is directed to the field of structures that are added to the top surface of boats. Generally the structures are located over the “bridge deck” area of the boat, typically encompassing the operator station of the boat. These structures are used to support a cover to provide shade and weather protection over the operator's station as well as to support antennas and other items. These structures with covers are known generally in the art as “hardtops.”

The available “hardtops” or boat covers are fabricated from a cored fiberglass part molded with an inner and outer skin. The fabrication of available hardtops may be performed in a permanent mold, where an inner and outer shell are bonded together. At the higher price end of the recreational boat aftermarket, a temporary mold is made, and the hardtop is laminated with a balsa or synthetic core material between two layers of fiberglass. The hard top is then mounted on and supported by a welded metal structure usually aluminum. This type of construction is extremely labor intensive and as a result a hardtop for a small 25-26 foot boat will sell for $5-6,000 going up to $30,000 for boats in the 50-60 foot range. However, despite the cost, the appearance of this type of construction is the most sought after in the boat aftermarket.

A significant trend in structures on boats today is away from canvas or fabric tops to permanent hardtops. For the past 25 years or so hardtops have been manufactured in one of two ways. Before that they were typically wood, or wood covered with fiberglass.

Another method is a fiberglass panel or sheet of fiberglass supported by a structure of standard aluminum extrusion profiles. One of the difficulties with this construction is finishing the edge in a manner that looks professionally fabricated and not “homemade”. Among the prior methods were the use of moldings of various types including using a square or rectangular extrusion on the perimeter and a “j” molding to clamp the fiberglass to the top and “trim” the edge. The advantage to this method is that it is relatively easy to make a wide variety of shapes and sizes without expensive molds or tooling. As a result, it is used widely but almost exclusively in the aftermarket.

One object of the present invention is to allow construction of hardtops with the ease of the second method and the look of the first. Another object is to create such hardtops which are ⅓ to ½ the weight of cored glass tops, and about ⅓ to ½ the cost of manufacture.

SUMMARY OF THE INVENTION

A hardtop for a boat includes a peripheral frame and a panel sized and shaped so as to cover a central opening in the frame. An inboard portion of the frame is provided with receiving means, such as a notch or pocket, for receiving a peripheral edge of the panel such that an exterior surface of the panel is substantially flush with an upper edge of the frame in close proximity thereto. Even if the frame is made from a plurality of tubular elements, the hardtop has the appearance of a one-piece (i.e., seamless) structure. In addition, the hardtop has clean (i.e., trim) edges which further enhance its aesthetic appearance.

In one embodiment, the hardtop employs only an upper panel. Alternatively, two panels may be employed, one being oriented flush with the upper edge of the frame and the other being oriented flush with a lower edge of the frame. Both embodiments are adapted for positioning above an operator station of the boat.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference is made to the following detailed description of various exemplary embodiments considered in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a typical installation of a boat with a hardtop installed over its operating station.

FIGS. 2A-2C illustrate one embodiment of a hardtop constructed in accordance with the present invention.

FIG. 3 is an exploded perspective view of the embodiment illustrated in FIGS. 2A-2C.

FIGS. 4A-4C illustrate a second embodiment of a hardtop constructed in accordance with the present invention.

FIG. 5 illustrates a third embodiment of a hardtop constructed in accordance with the present invention.

FIG. 6 illustrates a fourth embodiment of a hardtop constructed in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Although the present invention can be used in many different locations on a boat or the like, it is particularly suitable for use in connection with a boat's operator station. Accordingly, the present invention will be described hereinafter in connection with such a station. It should be understood, however, that the following description is only meant to be illustrative of the present invention and is not meant to limit the scope of the present invention, which has applicability to other areas of a boat, such as its after-deck and/or its cockpit.

Referring to FIG. 1, a hardtop 10 constructed in accordance with the present invention is mounted on a boat 12 above an operator station 14. The hardtop 10 sits atop a deck-mounted support structure 16, such as the one disclosed in Tull U.S. Pat. No. 6,725,799, whose disclosure is incorporated herein by reference.

With continued reference to FIG. 1, the hardtop 10 includes a generally rectangular frame 18, which delimits the periphery of the hardtop 10 and which will be described in greater detail hereinafter. The rectangular shape of the frame 18 is especially suitable where the hardtop 10 is used in connection with the operator station 14 of the boat 12. It should be understood, however, that the frame 18 can have shapes and sizes which conform to other areas of the boat 12, such as an after-deck (not shown) or a cockpit (not shown), resulting in hardtops of various different sizes and shapes.

The topside of the hardtop 10 is formed by a generally planar top panel 20, whose construction and function will be described in greater detail below. Similarly, the underside of the hardtop 10 is formed by a generally planar bottom panel 22, whose function and construction will also be described in greater detail below.

FIGS. 2A-2C are cross-sectional views showing various portions of the hardtop 10, especially the frame 18 and the top and bottom panels 20, 22, respectively. As can been seen in FIGS. 2A and 2C, the frame 18 is constructed from tubular member(s) 24 having a profile (i.e., cross-sectional shape) which resembles a keyhole oriented sideways. An outboard portion 26 of each tubular member 24 is rounded off for aesthetic purposes, as well as for safety reasons (i.e., the avoidance of sharp edges). An inboard portion 28 of each tubular member 24 is squared off because the panels 20, 22 hide it from view and render it inaccessible to the operator or other occupants of the boat 12.

With continued reference to FIGS. 2A and 2C and with further reference to FIG. 3, the inboard portion 28 of each tubular member 24 is provided with a pair of notches 30, 32, one (i.e., notch 30) facing the topside of the hardtop 10 and the other (i.e., notch 32) facing the underside of the hardtop 10. The notches 30, 32 are sized and shaped so as to receive corresponding edges of the top and bottom panels 20, 22, respectively. More particularly, the notch 30 provides each tubular member 24 with an upper shoulder 34 and an upper ledge 36, while the notch 32 provides each tubular member 24 with a lower shoulder 38 and a lower ledge 40. The functions of the upper and lower shoulders 34, 38, respectively, and the upper and lower ledges 36, 40, respectively, will be described hereinafter.

As can be seen best in FIGS. 2A and 2C, the notch 30 has a depth which is essentially the same as the thickness of the top panel 20, while the notch 32 has a depth which is essentially the same as the thickness of the bottom panel 22. As a result of this dimensional relationship, when the panels 20, 22 are inserted into the notches 30, 32, the top panel 20 lies flush with an adjacent upper edge 42 of each tubular member 24, while the bottom panel 22 lies flush with an adjacent lower edge 44 of each tubular member 24. This dimensional relationship also allows the top panel 20 to rest on the upper ledge 36 in abutment with the upper shoulder 34 of each tubular member 24, while the bottom panel 22 rests on the lower ledge 40 in abutment with the lower shoulder 38 of each tubular member 24.

The tubular member(s) 24 can be made from any suitable material, such as extruded aluminum. The panels 20, 22 can be made from any suitable material, such as rigid fiberglass. Any conventional means can be employed to attach the panels 20, 22 to the tubular member(s) 24.

Even though it is assembled from several individual parts, the hardtop 10 has the appearance of a one-piece (i.e., seamless) structure (see FIGS. 2A and 2C). Moreover, the assembled hardtop 10 has clean (i.e., “trim”) edges which further enhance its aesthetic appearance (see FIGS. 2A and 2C).

Depending upon the size of the hardtop 10, it may be necessary to provide the frame 18 with an intermediate structure 46 in order to maintain the desired spacing between the top panel 20 and the bottom panel 22 (see FIG. 2B). If required, any such structure would be made out of a material that would lend itself to attachment to the other component parts of the hardtop 10 by any suitable conventional means. Alternatively, the top and bottom panels 20, 22 may be replaced with a single (e.g., composite) panel (not shown) which is equal in thickness to the frame 18, thereby eliminating the need for the intermediate structure 46.

FIGS. 4A-4C are cross-sectional views of an alternate embodiment of the hardtop 10 depicted in FIGS. 1-3. In the alternate embodiment of FIGS. 4A-4C, there is no bottom panel. Accordingly, there is shown a hardtop 110 made from a frame 118 and a single (i.e., top) panel 120. In describing the alternate embodiment of FIGS. 4A-4C, elements corresponding to elements of the embodiment shown in FIGS. 1-3 will be designated by corresponding reference numerals increased by one hundred. Unless otherwise stated, any such corresponding elements will have the same features and functions as their counterparts in FIGS. 1-3.

Since the hardtop 110 has only one panel (i.e., the top panel 120), each tubular member 124 requires but a single (i.e., upper) notch 130. Depending upon the size of the hardtop 110, there may still be a need for a support structure 146 to prevent the top panel 120 from sagging (see FIG. 4C).

FIG. 5 is cross-sectional view of another alternate embodiment of the hardtop 10 depicted in FIGS. 1-3. In describing the alternate embodiment of FIG. 5, elements corresponding to elements of the embodiment shown in FIGS. 1-3 will be designated by corresponding reference numerals increased by two hundred. Unless otherwise stated, any such corresponding elements will have the same features and functions as their counterparts in FIGS. 1-3.

Continuing to refer to FIG. 5, a hardtop 210 is made from a frame 218 and a single (i.e., top) panel 220. The frame 218 is made from tubular member(s) 224, each of which has an oval cross-sectional shape. Rather than being notched like their counterparts in the two previously described embodiments, an inboard portion 228 of each tubular member 224 is provided with a recessed pocket 248 sized and shaped to receive a tongue 250 formed on an undercut end 252 of the top panel 220. By undercutting the end 252 of the top panel 220, an upper (i.e., exposed) surface 254 of the top panel 220 can be aligned evenly with, and in close proximity to, an upper edge 256 of an adjacent tubular member 224, thereby providing the hardtop 210 with a trimmed appearance.

FIG. 6 is cross-sectional view of yet another alternate embodiment of the hardtop 10 depicted in FIGS. 1-3. In describing the alternate embodiment of FIG. 6, elements corresponding to elements of the embodiment shown in FIGS. 1-3 will be designated by corresponding reference numerals increased by three hundred. Unless otherwise stated, any such corresponding elements will have the same features and functions as their counterparts in FIGS. 1-3.

With continued reference to FIG. 6, a hardtop 310 is made from a frame 318 and a single (i.e., top) panel 320. The frame 318 is made from tubular member(s) 324, each of which has a rectangular or square cross-sectional shape. Rather than being notched like their counterparts in the first two embodiments, an inboard portion 328 of each tubular member 324 is provided with a recessed pocket 348 sized and shaped to receive a tongue 350 formed on an undercut end 352 of the top panel 320. By undercutting the end 352 of the top panel 320, an upper (i.e., exposed) surface 354 of the top panel 320 can be aligned evenly with, and in close proximity to, an upper edge 356 of an adjacent tubular member 324, thereby providing the hardtop 310 with a trimmed appearance.

As can be seen in FIG. 6, the thickness of the top panel 320 is less than the thickness of the frame 318. If additional support is required for the top panel 320, an element similar to the structure 146 (see FIGS. 4B and 4C) can be provided. The need for any such additional support structure may be obviated by replacing the top panel 320 with a panel 320′ (shown in phantom in FIG. 6) having a thickness equal to, or even greater than, the thickness of the frame 318.

It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention. All such variations and modifications are intended to be included within the scope of the invention as defined by the appended claims. 

1. A hardtop for a boat, comprising a peripheral frame defining a central opening, said frame including an inboard portion, an outboard portion, an upper edge, and a lower edge; a panel sized and shaped so as to cover said central opening of said frame, said panel having a peripheral edge and an exterior surface; and receiving means, formed in said inboard portion of said frame, for receiving said peripheral edge of said panel such that said exterior surface of said panel is substantially flush with said upper edge of said frame in close proximity thereto.
 2. A hardtop according to claim 1, wherein said frame includes a plurality of tubular members, each pair of adjacent tubular members being connected in end-to-end fashion to form said frame.
 3. A hardtop according to claim 2, wherein said receiving means includes a plurality of notches, one in each of said tubular members.
 4. A hardtop according to claim 3, wherein said notches of each pair of adjacent tubular members are in substantial alignment with each other.
 5. A hardtop according to claim 4, wherein each of said notches is positioned proximate said upper edge of a corresponding one of said tubular members.
 6. A hardtop according to claim 2, wherein said receiving means includes a plurality of pockets, one in each of said tubular members.
 7. A hardtop according to claim 6, wherein said pockets of each pair of adjacent tubular members are in substantial alignment with each other.
 8. A hardtop according to claim 7, wherein each of said pockets in positioned intermediate said upper and lower edges of a corresponding one of said tubular members.
 9. A hardtop according to claim 7, wherein each of said pockets is positioned proximate said upper edge of a corresponding one of said tubular members.
 10. A hardtop according to claim 7, wherein said peripheral edge of said panel has a tongue sized and shaped so as to be received in said aligned pockets of said tubular members.
 11. A hardtop according to claim 10, wherein said tongue is formed by an undercut in said peripheral edge of said panel.
 12. A hardtop according to claim 2, wherein said panel is made from fiberglass.
 13. A hardtop according to claim 12, wherein each of said tubular members is made from aluminum, said outboard portion thereof having a rounded profile.
 14. A hardtop according to claim 1, wherein said receiving means includes a notch extending continuously around said frame in said inboard portion thereof, said notch being located proximate said upper edge of said frame.
 15. A hardtop according to claim 1, wherein said receiving means includes a pocket extending continuously around said frame in said inboard portion thereof.
 16. A hardtop according to claim 15, wherein said pocket is located intermediate said upper and lower edges of said frame.
 17. A hardtop according to claim 15, wherein said pocket is located proximate said upper edge of said frame.
 18. A hardtop according to claim 1, further comprising another panel sized and shaped so as to cover said central opening of said frame, said another panel having a peripheral edge and an exterior surface, and another receiving means, formed in said inboard portion of said frame, for receiving said peripheral edge of said another panel such that said exterior surface of said another panel is substantially flush with said lower edge of said frame in close proximity thereto.
 19. A hardtop according to claim 18, wherein said panel and said another panel are maintained in a spaced apart relationship relative to each other by a support structure extending across said frame between said panels.
 20. A hardtop according to claim 1, further comprising mounting means for mounting said hardtop above an operator station of a boat. 